Method and Installation for Manufacturing a Floor Covering Product and Floor Covering Product Obtained Hereby

ABSTRACT

A method for manufacturing a floor covering product comprises at least a first step of forming a single- or multi-layered substrate by consolidating synthetic material-based starting material. The method comprises a second step after the first step, which is performed in line with the first step. The at least one continuous film is laminated onto the substrate, and the laminating is performed by means of a belt press.

This invention relates to a method and installation for manufacturing afloor covering product and to a floor covering product obtained thereby.

More particularly, the invention relates to the manufacture of floorcovering products with a synthetic material-based substrate upon whichat least one film is laminated.

The film laminated thereon may be of any kind. In the first place,however, a printed film is meant, more particularly a decor film.However, this may also relate to another film, such as a filmfunctioning as a wear layer. Also, a plurality of films may be laminatedthereon, for example, the decor film with thereabove a film functioningas a wear layer.

In particular, however, not restrictive, the invention aims at themanufacture of floor covering products, the substrate of which is formedof thermoplastic synthetic material.

More particularly, the invention relates to the production of syntheticmaterial-based floor panels which can be provided as a floor covering ona supporting underlying floor. Generally, such floor panels are known asvinyl tiles, also called LVT (Luxurious Vinyl Tiles), as up to now theymostly are realized on the basis of vinyl. Although the invention in thefirst place also aims to vinyl tiles, it is clear that it does notrestrict itself to this synthetic material, however, is also applicableto tiles, more particularly floor panels of which at least the substrateis realized on the basis of other synthetic materials, for example,polypropylene (PP), polyethylene (PET) or polyurethane (PUR).Preferably, this relates to semi-rigid or soft synthetic materials,which to this aim may be provided, for example, with plasticizers.

Said film, films, respectively, laminated on the substrate, may consistof any suitable synthetic material, however, preferably a PVC film isapplied. Other examples are PU, PP and PET films. In the case of a PPfilm, this may relate, for example, to an oriented polypropylene film.In the case of a PVC film, this preferably relates to a hard PVC film,namely, a film on the basis of PVC without plasticizer or with an amountof plasticizer of less than 5 percent by weight. Such hard PVC film canbe printed with a higher precision, certainly in the case of a printperformed with water-based inks. In such case, a drying operation bymeans of heat supply is desirable in the printing process, however, bychoosing hard PVC the possible expansion of the film is restricted. Thewear layer preferably also comprises a thermoplastic material, such assoft or hard PVC, PU, PP or PET. Preferably, the transparentthermoplastic wear layer is free from solid additives, such as ceramicparticles for promoting wear resistance, although this kind of particlesis not excluded. However, the inventor has found that they may beomitted in view of obtaining a good transparency, whereas still anacceptable wear resistance is kept.

According to an alternative, it is not excluded that the printed decoror the print may be provided on the underside of the wear layer, whereinthen no separate film will be necessary for applying the decor. Ifindeed specifically a film is applied for the decor, the print can beprovided either on the upper side only, or on the lower side only, orboth on the upper side and the lower side.

Such tiles actually relate to floor panels which either may be square,or rectangularly oblong, or may have any other shape.

Herein, the possibly provided decor may form a representation of a woodmotif or stone motif, or any other motif, such as a fancy pattern.

On the surface of such products, for example, said vinyl tiles, astructure may be provided, formed by impressions, such as a wood orstone structure, respectively. Other impressions may be applied as well,for example, in order to imitate deeper-located joints or the like.Further, it is also known that such structure can be performed incorrespondence with the printed motif, which in English is called“registered embossed”. By such “correspondence”, as is known, has to beunderstood that the structure is performed according to a motif which isadapted to the printed motif and that consequently the impressionscannot be provided randomly in respect to the printed motif.

The invention aims at a method with which such and other floor coveringproducts can be realized in a particularly smooth manner, such bysuccessively linking very specific production steps, wherein at the sametime a good, thus, high-quality lamination of a film on a substrate insuch production process is striven for.

To this aim, the invention, according to a first aspect, relates to amethod for manufacturing a floor covering product, wherein this methodcomprises at least a first step of forming a single- or multi-layeredsubstrate by consolidating synthetic material-based starting material,as well as comprises a second step after the first step, whichpreferably is performed in line with the first step, wherein at leastone continuous film is laminated onto the substrate, characterized inthat said laminating is performed by means of a belt press. Byperforming the lamination after the consolidation of the substrate, andalso by realizing this lamination by means of a belt press, ahigh-quality end product can be obtained with great certainty. As,during laminating, it is started from an already substantiallyconsolidated product, optimum starting conditions for laminating arecreated. As, during laminating, a belt press is used, wherein thus acontact is maintained over a longer distance, possible inaccuracies willbe flattened further and/or a good lamination can be guaranteed, with aminimum of deformations.

Preferably, the one or more films in transport direction are clampedbetween a belt of the belt press and the substrate at least over alength of at least 0.5 m and still better at least 1 meter.

It is noted that continuous lamination processes have already been knownpreviously, however, not with the use of a belt press.

Further characteristics of the invention are described in the appendedclaims.

According to the most preferred embodiment, the forming of the substrateis performed by means of a strewing process, wherein the syntheticmaterial-based starting material is strewn as a granulate or in anyother manner and subsequently is consolidated in a press device. It hasbecome apparent that a strewing process offers a good starting basis inorder to subsequently apply thereto a lamination according to theinvention. So, for example, a very smooth surface is obtained aftercompressing the strewn material, by which a good underlying surface isobtained for laminating the continuous film.

Preferably, the strewn granulate or the like is consolidated by means ofa continuous press, more particularly a belt press, and in particular adouble-belt press. The use of a belt press also promotes the smoothnessof the product obtained therefrom.

However, the aforegoing does not exclude that according to analternative the substrate can be formed by means of extrusion,preferably an extrusion in which the synthetic material-based material,more particularly starting material, is extruded in a layer shape, or bymeans of a comparable process, wherein possibly a plurality of layersare thermally laminated on top of each other.

Preferably, the step of forming the substrate shows one or more of thefollowing characteristics:

that in the starting material one or more other materials than syntheticmaterial are incorporated, such as additives and/or fillers, amongstwhich chalk;

that reinforcement material, more particularly fibers, are incorporatedinto the substrate, preferably in the form of one or more local layersin the form of a fiber mat, non-woven or fabric, for example, in theform of glass fiber, such as a glass fiber fleece, cloth or net.

Preferably, said laminating of the continuous film in the second step isperformed by means of a double-belt press.

In particular, it is preferred that said laminating of the continuousfilm in said second step is performed by means of a belt press which ismade as an isobaric press. This offers a considerable advantage. Herebyin fact a very uniform lamination can be effected.

More particularly, it is preferred that said laminating of thecontinuous film in said second step in the belt press is performed bymeans of a fluid pressure which is exerted on a surface of a belt of thebelt press, more particularly in a zone along which this belt is moving.

Preferably, in said second step a double-belt press is applied, whereinthe substrate and the continuous film are moved along between the twobelts of the double-belt press, wherein the fluid pressure is exerted onthe belt which is situated on the side of the continuous film, whereasthe other belt functions as a counter support.

According to an alternative possibility, for said laminating in saidsecond step, instead of the aforementioned belt press use is made ofanother press, which press, however, is an isobaric press, moreparticularly is a press which presses the film directly or indirectlywith a uniform fluid pressure over a surface of the substrate onto thislatter. It is clear that any form of isobaric pressing process leads toan advantageous result.

Preferably, for creating the pressure in the press use is made of agaseous fluid, more particularly air, or according to an alternative ofa liquid, for example, oil.

From a practical point of view, it is preferred that said laminating ofthe film on the substrate is performed by fusion.

Thus, it is preferred that in order to provide for a fusion, thesubstrate and/or the film to be provided thereon by lamination arebrought to a suitable temperature, before, during or after joining thesubstrate and the film. The value of the temperature to be applied isthe value at which a fusion takes place and as such is known and/or canbe determined by a person skilled in the art in a simple manner.

The aforementioned temperature can be effected, for example, by means ofor at least in part by one or more of the following possibilities:

by applying heat, which is present in the substrate, originating fromsaid first step;

by adding heat to the substrate and/or to the continuous film betweenthe first and second steps or during the second step.

According to a preferred embodiment, during the second step heat issupplied via a heated roller placed at the starting point of the beltpress, preferably a deflection roller of a belt of the press which comesinto contact with the continuous film.

Towards the end of the lamination, preferably a cooling is provided inorder to consolidate the assembly of substrate and film. To this aim,for said laminating use may be made of a fluid pressure which isdirectly or indirectly exerted on a surface of a belt of the belt press,wherein the cooling is performed via this fluid.

It is noted that said continuous film preferably is a decor film andmore particularly a film which is provided with a print. Such print canbe realized beforehand at a printer's, however, according to a preferredalternative of the invention, the film forming the decor layer isprinted directly, thus, during the manufacturing process, however, priorto laminating, preferably by means of a digital printer or printingunit. It is also not excluded to realize the print after laminating, orpartially before and partially after, however, preferably beforepossible impressions for forming a relief are provided in the surface.

In a preferred embodiment, impressions are provided in the upper side ofthe floor covering product, too, more particularly in the samecontinuous process, preferably after laminating the continuous film ontothe substrate.

Preferably, the floor covering product comprises a printed decor and theimpressions are realized as so-called “in register” with the decor.

In a particular embodiment, the impressions are provided by means of a,whether or not multi-part, roller, which is provided with a relief onits surface.

More particularly, it is preferred that a roller is applied with, seenalong the circumference, at least two segments which each are providedwith a relief, wherein in circumferential direction the distance betweenat least two of these segments is adjustable in order to change theso-called “repeat” with which the impressions are realized, wherein this“repeat” is adjusted and changed in function of the position of thedecor.

Preferably, the method herein is also characterized in that thesubstrate and said continuous film, whether or not together with stillother layers, form a material web and that this material web is bentaround the aforementioned roller, such that the cooperation between therelief and the material web at least takes place over an arc-shapedportion. More particularly, it is preferred that the material of thematerial web is kept in contact with the roller during at least 3seconds, and still better at least 5 seconds. It is also preferred thatthe material web is supplied to the roller in heated condition and thatthe roller is cooled.

Other techniques for providing impressions “in register” of course canalso be applied, or different techniques can be combined, too.

According to a possibility of the invention, it is characterized in thatsaid continuous film is a decor layer and that this film is subjected toa controlled stretching prior to laminating, in order to stretch thedecor to a larger or lesser extent, in the width and/or length, suchthat the decor is adjusted in function of the desired final result.

The floor covering product can be provided with a translucent wearlayer, for example, in the form of at least one film and/or in the formof at least one lacquer layer.

In a preferred application, the method is characterized in that thesubstrate and said continuous film, whether or not together with stillother layers, form a material web and that this material web is cut tofloor panels, more particularly to rectangular oblong or square panelsor tiles.

According to a particular embodiment, the floor panels are formed suchthat they are free from coupling parts at their edges, wherein the floorpanels are of the type which is intended for being installed accordingto the “loose lay” principle, or for being installed by means of gluingto the underlying surface.

According to another possibility, the method is characterized in thatthe floor panels are provided with coupling parts at their edges,whereby a plurality of such panels can be coupled to each other at theiredges in a mechanical manner in order to thereby provide for a lockingpreferably horizontally as well as vertically.

The method of the invention preferably is applied for the production ofso-called LVT tiles (Luxurious Vinyl Tiles) or comparable floor panels.

According to a variant of the invention, instead of using saidcontinuous film, use is made of successive film sheets which arelaminated on the continuously formed substrate.

Preferably, the substrate shows one or more of the followingcharacteristics:

the material of the substrate contains a thermoplastic;

the material of the substrate contains a supple thermoplastic, moreparticularly a thermoplastic which is provided with a plasticizer;

the material of the substrate is based on any of the followingmaterials: polyvinyl chloride (PVC), polypropylene (PP), polyethylene(PET) or polyurethane (PUR);

the material of the substrate contains one or more filler materials, forexample, chalk;

the material of the substrate, either across the entire thicknessthereof, or across only a portion of the thickness thereof,substantially consists of a composite of synthetic material and woodparticles, and more particularly WPC (Wood Plastic Composite), whereinfor the synthetic material preferably use is made of any of the hereinabove-mentioned synthetic materials;

the substrate consists of at least two layers, namely, a layer such asdescribed in the preceding paragraph, and a layer which is free orsubstantially free from wood particles and substantially is based onsynthetic material;

the substrate contains a reinforcement layer, such as a glass fiberfleece or the like.

Preferably, the continuous film shows one or more of the followingcharacteristics:

it relates to a thermoplastic synthetic material film;

it relates to a PVC film, PU film, PP film, or PET film;

it relates to an oriented polypropylene film;

it relates to a hard PVC film, namely, a film on the basis of PVCwithout plasticizer or with an amount of plasticizer of less than 5percent by weight.

According to a particularly preferred aspect, the method ischaracterized in that the substrate, starting from its manufacture up tothe forming of the final floor covering product, is handled in a flatstate, or, during bending, is subjected exclusively to bending having aradius of more than 40 cm. In this manner, relatively thick materialwebs can be formed in a smooth manner.

According to the invention, it is not excluded that simultaneously, bywhich is intended in the same production process, or possibly preciselyat the same time, two or more films, more particularly syntheticmaterial films, are provided by means of said lamination.

By further combining very specific techniques with each other inpreferred embodiments, as discussed herein above, a method is obtainedwhich in many respects can be universally applied, wherein also a largerpossibility is offered for realizing various products, starting from oneand the same belt press, with minor adjustments, for example, withdifferent features and/or of a different construction.

In a preferred embodiment, according to the invention floor coveringproducts of a very small thickness as well as of a larger thickness, andthus more difficult to bend, can be realized. Practical values ofthicknesses are 2 to 6 mm.

Although the invention in the first place relates to floor panels, itcan also be applied for the production of wall-to-wall floor coveringproducts, such as vinyl, which is marketed on rolls.

It is noted that of course it is not excluded to provide a backing layeror underlying layer on the underside of the substrate, such as avapor-tight layer, for example, a thermoplastic film.

A lacquer layer can be provided as the uppermost layer of the floorcovering product. Herein, this may relate, for example, to an UV- or anelectron beam-hardening lacquer layer and/or to a PU lacquer layer. Suchlacquer layer may replace said film functioning as a wear layer,however, may also be applied hereon as an additional layer.

Preferably, the invention, as already stated herein above, is appliedfor manufacturing floor panels, which are provided with mechanicalcoupling means, more particularly coupling parts, on the respectiveedges, which allow that two of such floor panels can be coupled to eachother in such a manner that a locking is obtained in a verticaldirection perpendicular to the plane of the coupled panels, as well asin a horizontal direction perpendicular to the coupled edge and in theplane of the panels. Preferably, the coupling means also show one or acombination of two or more of the following features:

the feature that the mechanical coupling means or coupling partssubstantially are made as a tongue and a groove bordered by an upper lipand a lower lip, wherein this tongue and groove substantially areresponsible for the locking in said vertical direction, and wherein thetongue and the groove are provided with additional locking partssubstantially responsible for the locking in said horizontal direction.Preferably, the locking parts comprise a protrusion on the lower side ofthe tongue and a recess in the lowermost groove lip. Such coupling meansand locking parts are known, for example, from WO 97/47834;

the feature that the mechanical coupling means or coupling parts pressthe coupled floor panels against each other, for example, in that thesemechanical coupling means are realized with so-called pre-tension, as isknown as such from EP 1 026 341. The tensioning force with which thefloor panels are pressed against each other or towards each other may beobtained, for example, in combination with the above feature, by meansof a lower lip, which is bent out in coupled position and which, tryingto spring back, presses against the lower side of the tongue;

the feature that the mechanical coupling means allow a coupling by meansof a horizontal, or quasi-horizontal, shifting movement of the panelstowards each other;

the feature that the mechanical coupling means allow a coupling by meansof a turning movement along the respective edges;

the feature that the mechanical coupling means allow a coupling by meansof a downward-directed movement of a male coupling part having, forexample, a tongue, up into a female coupling part having, for example, agroove, preferably in order to install such panels according to theso-called “fold-down” principle;

the feature that the mechanical coupling means, or at least thepertaining upper edge, is realized by means of a milling treatment withrotating milling tools.

Preferably, said coupling means are realized substantially in saidsubstrate, more particularly at least in at least one of said two layerswhich, according to the invention, enclose the glass fiber layer.Preferably, said coupling means are provided by means of a millingtreatment with rotating milling tools. Preferably, the floor panel ofthe invention relates to a rectangular, either oblong or square, panelwhich is provided with mechanical coupling means on both pairs ofopposite edges.

Panels which are provided with coupling means preferably have athickness of at least 2.5, still better at least 3 millimeters.

It is not excluded that, also as stated herein above, the invention isapplied for panels which are free from coupling means or coupling partsat their edges, wherein these panels then are intended for being gluedwith their underside to the underlying surface or for being installedloosely. Such panels preferably have a thickness of less than 6, andstill better less than 4 millimeters, however, preferably of more than1.5 millimeters.

Prior to laminating said film onto the substrate, possibly a levellingtreatment may be performed on the surface of the substrate. Thelevelling treatment may consist, for example, of a grinding treatmentand/or providing one or more layers of plastisol. Preferably, thislevelling treatment is performed in line with the steps of thesubstrate.

The present invention also relates to an installation for manufacturinga floor covering product, more particularly for realizing theaforementioned method, characterized in that it consists at least of adevice for forming a single- or multi-layered substrate by consolidationof synthetic material-based starting material, as well as a deviceconnected thereto for laminating at least one preferably continuous filmon the substrate, wherein this latter device makes use of a belt press.

In a preferred embodiment, the installation is provided with a presswith features as described herein above.

The installation possibly may comprise a device for forming impressionsin order to provide the floor covering product with a relief on itssurface, wherein for this device preferably use is made of a roller asdescribed herein above.

The installation also may comprise a printing device, preferably adigital printer, with which a decor is printed on the continuous film,preferably while this film is supplied to the device for laminating.

Further, the installation may also comprise one or more additionaldevices and/or comprise additional provisions for effecting one or moreoperations of the herein above-described method.

According to a second aspect, the invention also relates to a method formanufacturing a floor covering product, wherein this method comprises atleast a first step for forming a single- or multi-layered substrate byconsolidating synthetic material-based starting material, as well ascomprises a second step after the first step, which preferably isperformed in line with the first step, wherein at least one continuousfilm is laminated on the substrate, and also comprises a third step,wherein impressions are formed in the surface, with the characteristic:

that the forming of the substrate is performed by means of a strewingprocess, wherein the synthetic material-based starting material isstrewn as a granulate and subsequently is consolidated in a pressdevice; and

that the impressions are provided by means of a roller, which isprovided with a relief on its surface, wherein for this roller a rolleris applied with, seen along the circumference, at least two segments,which each are provided with a relief, wherein in circumferentialdirection the distance between at least two of these segments isadjustable in order to change the so-called “repeat” with which theimpressions are realized, wherein this “repeat” is adjusted and alteredin function of the position of an applied decor.

According to this second aspect, the laminating step is of lessimportance and may take place in any manner. The combination of forminga substrate by means of a strewing process and the use of an adjustableroller for providing impressions in register already leads to aparticularly smooth production process. All other characteristics whichare described by means of the first aspect and the claims thereof, ofcourse may also be applied in combination with the second aspect.

All partial features from the first aspect can be employed at choice inthe method of the second aspect.

In the first as well as in the second aspect, of course the films to belaminated are thin films and preferably have a thickness of less than 1mm, and still better less than 0.5 mm and even better less than 0.2 mm.

It is clear that the invention also relates to floor covering productssuch as obtained by the aforementioned methods and/or by the applicationof the aforementioned installation.

With the intention of better showing the characteristics of theinvention, herein below, as an example without any limitative character,some preferred embodiments are described, with reference to theaccompanying drawings, wherein:

FIG. 1 schematically illustrates a possible embodiment of the method ofthe invention, as well as schematically represents the installationapplied therewith;

FIG. 2 represents a variant.

In the accompanying FIG. 1, an installation 1 according to the inventionis represented, which consists at least of a device 2 for forming asubstrate 3 by consolidation of synthetic material-based startingmaterial 4, as well as a subsequent device 5 for laminating at least onepreferably continuous film 6 on the substrate 3, wherein thislast-mentioned device 5, for the lamination makes use of a belt press 7,such that the film 6 is pressed, at least over a well-defined distance,in contact with the substrate 3.

The device 2 preferably is of the type wherein the substrate is formedby means of a strewing process, wherein the synthetic material-basedstarting material 4 is strewn as a granulate in a strewing portion 8 ofthe device 2 and subsequently is consolidated in a press device or pressportion 9. As represented schematically, this press portion 9 preferablyconsists of a double-belt press 10.

The strewing portion 8 may be of a different construction and possiblymay also comprise supply means 11 for incorporating a reinforcementlayer, such as a glass fiber fleece 12, into the substrate.

As aforementioned and according to the first aspect of the invention,the device 5 comprises a belt press 7. In particular, it is preferredthat this belt press 7 is made as an isobaric press, wherein laminatingthe continuous film 6 in the belt press is performed by means of a fluidpressure P, which is exerted on a surface 13 of a belt 14 of the beltpress 7. As represented schematically, to this aim a chamber 15 may beformed along this belt, which chamber is bordered by a frame or border16, wherein in the thus formed chamber 15 a pressure can be built up,which pressure acts on the respective portion of the belt 14. In thismanner, a uniform pressure is realized during laminating, by which asmooth lamination is created.

It is clear that the belt press 7 preferably is a double-belt presshaving a second belt 17 which provides for the necessary support.

The use of an isobaric press shows the advantage that on the locationwhere the actual lamination is performed, a very uniform compressiontakes place, by which stresses in the plane of the substrate and thefilm practically are excluded, which leads to a uniform lamination

It is represented schematically that also still another film 18 can belaminated along. In a practical embodiment, the film 6 will be intendedfor forming a decor layer, whereas the film 18 forms a wear layer. It isnoted that it is not excluded to laminate, according a not-representedembodiment, the films 6 and 18 each by means of an own belt press 7,wherein then two belt presses 7 have to be installed one after theother.

It is noted that according to a not-represented variant, it is notexcluded to apply an isobaric press, wherein the fluid presses directlyon the respective film or films, without the intermediary of a belt orany other element.

Further, the method applied therewith may comprise also other steps,wherein the necessary devices and/or additional provisions to this aimthen are integrated into the installation.

So, for example, according to an important preferred embodiment, theinstallation is provided with a device 19 for forming impressions in thefloor covering product 20 to be formed. As represented in theaccompanying figure, to this aim preferably use is made of a roller 21with along the circumference at least two segments 22-23, which each areprovided with a relief 24-25, whether or not the same relief, wherein incircumferential direction the distance A1-A2 between at least two ofthese segments is adjustable in order to change the so-called “repeat”with which the impressions are realized, wherein this change preferablyis performed in function of the position of the decor, thisautomatically, and with the intention of producing so-called “registeredembossed” products.

At the entry of the device 19, a heating device 26, for example, bymeans of infrared radiation, can be provided for heating the upper sideof the respective material layer or material web 27, preferably almostup to melting temperature, in order to obtain that the impressions canbe realized. The roller 21 can be cooled in order to consolidate thethen realized impressions in the obtained form by the cooling down andstiffening of the material layer 27, the longer this material layer isin contact with the roller over a longer time.

Further, it is also represented schematically in the figure that theinstallation 1 also can be provided with a device 28 for subjecting thesubstrate at least on one side to an additional levelling treatment,such as, for example, a grinding machine.

As aforementioned, the film 6 is intended for forming a decor layer. Tothis aim, this film 6 can be supplied as a printed film from a supplyroll 29. According to an alternative, however, printing may also takeplace on site by means of a device 30, more particularly a printingdevice and in particular a digital printer or printing unit.

Also, it is not excluded to provide a further device 31 for subjectingthe film 6 to a certain stretching, preferably in a controlled manner,for adjusting the length and/or width of the decor, for example, infunction of an impression pattern to be provided afterwards.

In this manner, for example, by means of the device 31 an additionaladjustment of the width of the decor can be provided for, whereas bymeans of the device 19 an adjustment of the length is provided byadapting the average so-called “repeat”.

It is noted that it is not excluded to first have the belt press 7 bepreceded by one or more pressing rollers, although this preferably shallnot be the case.

At the entry of the belt press 7, preferably a heating is provided inorder to obtain that the respective film 6 and/of 18 and/or the surfaceof the substrate is sufficiently heated in order to come to aconsolidation by fusing. This heating may be performed by making use, atthe entry of the belt press 7, of a heated roller, more particularly adeflection roller 32. However, in the chamber 15 preferably a cooledfluid is applied, for example, cooled air, in order to obtain in thismanner a consolidation by stiffening after fusion.

According to an alternative, which may or may not be combined with theheating at the entry of the belt press 7, various temperatures can bemaintained in the chamber 15, or the chamber may also be subdivided intosegments in which different temperatures are prevailing. For example, onthe run-in side a high temperature may be maintained in order to promotefusing, whereas on the exit side cold air can be provided.

Finally, it is noted that in particular in respect to the effect of thestrewing process, on the one hand, and in respect to the realization ofimpressions with an adjustable roller, on the other hand, allinformation of the following patent applications has to be understood asbeing incorporated in the present application by reference:

WO 2013/179261

BE 2014/0517

PCT/IB2014/058464

In FIG. 2, a variant is represented with the particularity that thereinforcement material, and in particular the reinforcement layer, suchas the glass fiber fleece 12, is brought into contact with a plastisol,this in order to obtain a finally better consolidation and adherenceamong the various layers and to minimize the risk of a laterdelamination. In the example of FIG. 2, the plastisol is provided on thereinforcement layer, such as the glass fiber fleece 12, by means of aschematically represented device 34, whereby this penetrates in andthrough the glass fiber fleece and reaches the relatively rough surfaceof the lowermost strewn layer. In FIG. 2 is also shown that a secondlayer of starting material 4 is strewn here over. By providing for thatthe plastisol is gelled, a consolidated whole is obtained with a goodmutual adherence. For gelling the plastisol 33, of course the necessaryheat has to be supplied. In the represented example, this is realized bymeans of a heating device 35 installed between the device 34 and thesecond strewing device. It is noted that the heating may also take placeat other locations, for example, downstream of the second strewingdevice, whether or not in the press portion 9. It is noted that theplastisol possibly may also be supplied to the reinforcement layer 12before this latter is brought into contact with the strewn startingmaterial.

According to a not represented embodiment, after the application of thereinforcement layer and the plastisol no additional starting material isstrewn thereon, such that the plastisol forms the upper layer for thefurther process. In such case, it is even not excluded to add thereinforcement layer and the plastisol only after the press portion 9 andsubsequently guiding or not guiding it through an own press portion.

It is noted that the herein above-mentioned possibilities for using aplastisol as such form independent aspects of the present invention, inparticular where and how the plastisol is applied in combination withthe strewing. These independent aspects thus may be applied whether ornot in combination with the further downstream applied steps which weredescribed herein above. Thus, combinations with other, subsequentproduction techniques are not excluded.

Finally, it is also noted that it is not excluded to work, instead ofwith a device 30 for printing the film 6 which is installed at alocation before this film 6 is brought into contact with the substrate,with a device which provides a print after the film 6 is laminated ontothe substrate, and preferably prior to providing possible prints.

According to a deviating independent aspect of the invention, one ormore of the herein above-described production steps, which take placeduring said strewing, are combined with the application of a printdirectly on the formed material web, irrespective whether a film 6 isapplied or not. As an example, this means that, for example, the film 6is not provided and there is also no device 5, however, that at thatlocation a printing device for providing a print is present.

It is also noted that, when a transparent lacquer layer is provided,this latter can be provided before or after providing the impressions onthe final surface.

The present invention is in no way limited to the herein above-describedembodiments, on the contrary may such method and installation berealized according to various variants without exceeding the scope ofthe present invention. Moreover, the panels, instead as floor panels,may also be made as wall panels or ceiling panels or even as furniturepanels. Alternatively, the invention thus also relates to the samemethod as described herein above, however, then applied for theproduction of other panels than floor panels.

1-43. (canceled).
 44. A method for manufacturing a floor coveringproduct, the method comprising: a first step of forming a single- ormulti-layered substrate by consolidating synthetic material-basedstarting material; and after the first step a second step performed inline with the first step, wherein at least one continuous film islaminated onto the substrate, wherein said laminating is performed bymeans of a belt press.
 45. The method of claim 44, wherein the formingof the substrate is performed by means of a strewing process, whereinthe synthetic material-based starting material is strewn as a granulateand subsequently is consolidated in a press device.
 46. The method ofclaim 45, wherein the strewn granulate is consolidated by means of acontinuous press, more particularly a belt press, and in particular adouble belt press.
 47. The method of claim 44, wherein the forming ofthe substrate is performed by means of extrusion wherein the syntheticmaterial-based material is extruded in layer shape, or by means of acomparable process, wherein a plurality of layers are thermallylaminated on top of each other.
 48. The method of claim 44, wherein thestep of forming the substrate shows one or more of the followingcharacteristics: that in the starting material, one or more othermaterials than synthetic materials are incorporated, such as additivesand/or fillers, amongst others, chalk; that reinforcement material, moreparticularly fibers, are included in the substrate in the form of one ormore local layers in the form of a fiber mat, non-woven or fabric on thebasis of glass fiber.
 49. The method of claim 44, wherein saidlaminating of the continuous film in said second step is performed bymeans of a double belt press.
 50. The method of claim 44, wherein saidlaminating of the continuous film in said second step is performed bymeans of a belt press which is made as an isobaric press.
 51. The methodof claim 44, wherein said laminating of the continuous film in the beltpress in said second step is performed by means of a fluid pressurewhich is exerted on a surface of a belt of the belt press in a zonealong which this belt is moving.
 52. The method of claim 44, wherein insaid second step a double belt press is applied, wherein the substrateand the continuous film are moved along between the two belts of thedouble belt press, wherein the fluid pressure is exerted on the beltwhich is located on the side of the continuous film, wherein the otherbelt acts as a counter support.
 53. The method of claim 50, whereinduring laminating, in said second step, instead of said belt press useis made of another press, which press is an isobaric press for pressingthe film directly or indirectly with a uniform fluid pressure over asurface of the substrate onto this latter.
 54. The method of claim 50,wherein for creating the pressure in the press, use is made of a gaseousfluid, or according to an alternative, of a liquid.
 55. The method ofclaim 44, wherein laminating the film on the substrate is performed byfusing, and wherein for the purpose of providing a fusion, the substrateand/or the film to be provided thereon by lamination are brought to asuitable temperature.
 56. The method of claim 44, wherein towards theend of laminating, a cooling is provided for consolidating the assemblyof substrate and film, and wherein use is made of a fluid pressure whichis exerted directly or indirectly on a surface of a belt of the beltpress, wherein the cooling is performed via this fluid.
 57. The methodof claim 44, wherein said continuous film is a decor film provided witha print and wherein the decor layer is printed directly, thus, duringthe manufacturing process, however, prior to laminating, by means of adigital printer or digital printing unit.
 58. The method of claim 44,wherein impressions are provided in the upper side of the floor coveringproduct in one and the same continuous process after laminating thecontinuous film onto the substrate, and wherein the impressions arerealized as so-called “in register” with the decor.
 59. The method ofclaim 58, wherein the impressions are applied by means of a rollerprovided with a relief on its surface.
 60. The method of claim 44,wherein said continuous film is a decor layer and wherein this film,prior to laminating, is subjected to controlled stretching in order tostretch the decor to a greater or lesser extent, in the width and/orlength, such that the decor is adjusted in function of the desired finalresult.
 61. The method of claim 44, wherein the substrate and saidcontinuous film, whether or not together with still other layers, form amaterial web and wherein this material web is cut to floor panels torectangular oblong or square panels or tiles.
 62. The method of claim61, wherein it is applied for the production of so-called LVT tiles orcomparable floor panels.
 63. The method of claim 44, wherein instead ofusing said continuous film, use is made of successive film sheets whichare laminated on the continuously formed substrate.
 64. The method ofclaim 44, wherein the substrate shows one or more of the followingcharacteristics: the material of the substrate contains a thermoplastic;the material of the substrate contains a supple thermoplastic providedwith a plasticizer; the material of the substrate is based on any of thefollowing materials: polyvinyl chloride (PVC), polypropylene (PP),polyethylene (PET) or polyurethane (PUR); the material of the substratecontains one or more filler materials including chalk; the material ofthe substrate, either across the entire thickness thereof, or acrossonly a portion of the thickness thereof, substantially consists of acomposite of synthetic material and wood particles, and moreparticularly WPC (Wood Plastic Composite), wherein for the syntheticmaterial use is made of any of the herein above-mentioned syntheticmaterials; the substrate consists of at least two layers, namely, alayer such as described in the preceding paragraph, and a layer which isfree or substantially free from wood particles and substantially isbased on synthetic material; the substrate contains a reinforcementlayer, such as a glass fiber fleece or the like.
 65. The method of claim44, wherein the continuous film shows one or more of the followingcharacteristics: it relates to a thermoplastic synthetic material film;it relates to a PVC film, PU film, PP film, or PET film; it relates toan oriented polypropylene film; it relates to a hard PVC film, namely, afilm on the basis of PVC without plasticizer or with an amount ofplasticizer of less than 5 percent by weight.
 66. The method of claim44, wherein the substrate, starting from its manufacture up to theforming of the final floor covering product, is handled in a flat state,or, during bending, is subjected exclusively to bending having a radiusof more than 40 cm.
 67. A method for manufacturing a floor coveringproduct, the method comprising: at least a first step for forming asingle- or multi-layered substrate by consolidating syntheticmaterial-based starting material; a second step after the first stepperformed in line with the first step, wherein at least one continuousfilm is laminated on the substrate; a third step, wherein impressionsare formed in the surface, with the characteristic: that the forming ofthe substrate is performed by means of a strewing process, wherein thesynthetic material-based starting material is strewn as a granulate andsubsequently is consolidated in a press device; and that the impressionsare provided by means of a roller, which is provided with a relief onits surface, wherein for this roller a roller is applied with, seenalong the circumference, at least two segments, which each are providedwith a relief, wherein in circumferential direction the distance betweenat least two of these segments is adjustable in order to change theso-called “repeat” with which the impressions are realized, wherein this“repeat” is adjusted and altered in function of the position of anapplied decor.